Device and method for accepting a cut length of wire that has been formed into a coil

ABSTRACT

A swivel machine for wire processing including a coiler arranged between a cutting-off/insulation-stripping unit and a second swivel arm. The cut length of wire whose leading wire-end has been processed is coiled by a coiling disk of the coiler. After the leading wire-end of the cut length of wire has been processed, it is grasped by the coiler. A belt drive then advances the wire by the desired length of the cut length of wire, and simultaneously the coiler coils the advanced wire into a coil. After the coiling operation, a linearly movable stacker unit grasps the coil, and the coiling disk releases the coil. After the trailing wire-end has been processed, the stacker unit moves further in the wire-advance direction to the deposit. While the trailing wire-end is being processed, and while traveling to the deposit, the coil is provided with a bind.

FIELD OF THE INVENTION

The invention relates to a device and a method for accepting from acoiler a cut length of wire that has been formed into a coil, andtransporting it further to a deposit, according to the definition of theindependent patent claims.

BACKGROUND OF THE INVENTION

The patent application DE 42 35 007 A1 discloses a coiling device forcut lengths of wire wherein the inside walls of a drum serve as restingsurfaces for formation of the coil and thereby define the externaldiameter of the coil. In this device, while the wire is being inserted,the drum remains stationary and is opened when the wire length has beenattained and the coil bound. Following transfer of both wire-ends of thecoil to transfer grippers, subsequent wire-end processing operations as,for example, crimp pressing and/or seal loading, can be performed.Besides advantages from low moving masses, there are also disadvantagesas, for example, uncontrollable bending radii when inserting andcompressing the various coil layers for binding. Whether the individualwindings always lie against the wall is uncertain. Minimum bending radiion entry and emergence of the wire into, and out of, the drum are alsonot defined.

From patent specification EP 1 387 449 B1 a coiling device withcontrollable minimum bending radius for wires, especially optical-fiberwires, has become known. In this device, the cut length of wire iscoiled by means of a coiling unit into a coil, and after attaining thecorrect wire-length the wire-ends are of identical length and after thecoil has been bound, the wire-ends are accepted by transfer grippers forfurther processing. For optical-fiber wires the high outlay formechanics and controls is more readily justified than for wires withcopper conductors.

Patent application WO 03/018456 A1 discloses a coiling device for a coilwith a rotating coiling arbor, on which hanging and openable coilingarms are arranged. Depending on the cut length of wire, the arms areopened more or less, so that when the wire length is attained, the twowire-ends are approximately the same length. For processing of thewire-ends, after the coil has been bound it is accepted by transfergrippers.

On many types of wire processing machine, the handling of long cutlengths of wire (for example, greater than 7 meters wire length) isdifficult. On swiveling machines with swivel arms, the wire tray must beas long as the cut length of wire. On transfer machines with a transferunit that can be moved along straight lines, during transportationseveral loop-shaped wires lie on top of each other, which on rapidtransportation by means of the transfer unit can cause relatively highwire-pulling forces because the wire is only held at its ends.

In the said patent applications, solution concepts for transfer machinesare shown. Separate coiling devices downstream of the wire processingmachine have not established themselves because, with the serialprocessing operations, the cycle time or total processing time for acoiled cut length of wire was correspondingly long.

SUMMARY OF THE INVENTION

It is here that the present invention sets out to provide a remedy. Thepresent invention solves the problem of creating a device and a methodfor manufacturing long cut lengths of wire without lengthening the totalprocessing time.

The device according to the present invention is particularly suitablefor wire processing machines with swivel arms. The device according tothe present invention can, however, also be used on transfer machineswith linearly movable transportation units if additional grippers andreceiving devices for handling the wire-ends of the wire coil areprovided.

In the following exemplary embodiment of a wire processing machine withswivel arm, the coiler is arranged between acutting-off/insulation-stripping unit and a second swivel arm. Coilingof the cut length of wire takes place by means of a coiling disk which,by means of a controlled motor, depending on an also motor-controlledbelt drive, is rotatable, the belt drive serving to advance the wire andmeasure the length of the advanced wire. This arrangement isparticularly advantageous for elastic wires. The leading wire-end of thewire that is to be coiled is processed by means of processing stationsand, after processing, swiveled back to thecutting-off/insulation-stripping unit by means of a first swivel arm andadvanced with the belt drive a short distance, so that the coiler cangrip the leading wire-end. The belt drive then advances the wire by thedesired length of the cut length of wire, and the coiler coils theadvanced wire simultaneously into a coil. After the coiling operation, alinearly movable stacker unit grips the coil. When doing so, the coilingdisk pneumatically de-tensions its tension finger and travelspneumatically backwards. Profiled plates acting as remover prevent thecoil from being pulled backwards. The stacker unit then moves back withthe coil so that the trailing wire-end can be cut off and stripped ofinsulation and if necessary processed, a second swivel arm feeding thetrailing wire-end to processing stations. Grippers of the stacker unithold the coil, and the deposit unit moves until it is approximatelyunder the swivel point of the second swivel arm and the trailingwire-end can, if necessary, for processing of its end still be pulledout of the coil by means of the second swivel arm. After the trailingwire-end has been processed, the stacker unit moves further in thewire-advancing direction to the deposit. While the trailing wire-end isbeing processed, and during the travel to the deposit, the coil can beprovided with a bind. The coil can be provided with the bind duringprocessing of the trailing wire-end, or during processing of the leadingwire-end of the next cut length of wire. Thereafter, the bound coil canbe placed into containers, onto transportation belts, or onto otherreceptors as, for example, arbors.

The advantages achieved by means of the present invention are mainly tobe seen in that the binding operation on the coil proceedssimultaneously with the processing operation on the cut length of wire.The total processing time for the cut length of wire, also known as themachine cycle time, is thus not lengthened. The total processing timeremains the same with or without bind. The time for manufacturing thecoil is comparable with the time for placing into the deposit astraightened cut length of wire on a conventional wire processingmachine.

Mechanically, the coiler and stacker unit are not arranged as a separatedevice from the wire processing machine, but form an integral unit ofthe wire processing machine. The cut length of wire that is to bemanufactured and processed is cut off to length from the wire stock, itsleading wire-end processed, coiled, possibly its trailing wire-endprocessed, and as a coil with bind handed over to the deposit withoutany manual intervention being necessary.

Also advantageous is that the wire processing machine, despite long cutlengths of wire, is shorter dimensioned than a conventional wireprocessing machine. The length of the wire processing machine is notdetermined by the length of the cut length of wire.

In the wire processing machine according to the present invention, andin the method according to the invention for manufacturing andprocessing a cut length of wire, the cut length of wire is cut off tolength from a stock of wire and its wire-ends processed, a coiler beingprovided that forms the cut length of wire into a coil with at least onewinding, and a stacker unit with a binding device providing the coilwith a bind.

DESCRIPTION OF THE DRAWINGS

The above, as well as other advantages of the present invention, willbecome readily apparent to those skilled in the art from the followingdetailed description of a preferred embodiment when considered in thelight of the accompanying drawings in which:

FIG. 1 is a perspective view of a cut length of wire that is formed intoa coil;

FIG. 2 is a plan view of a wire processing machine according to thepresent invention;

FIG. 3 is a perspective view of the wire-processing machine shown inFIG. 2;

FIG. 4 is a perspective view of a coiler that forms the cut length ofwire into a coil;

FIG. 5 is a perspective view of the coiler shown in FIG. 4 viewed fromthe back;

FIG. 6 is a perspective view of linear guides of a coiling disk;

FIG. 7 is an exploded perspective view of the details of the coilershown in FIG. 4;

FIGS. 8 to 10 are perspective views of a tape station for preparing anadhesive tape;

FIGS. 11 and 12 are perspective views of a stacker unit during receptionof the adhesive tape; and

FIGS. 13 and 14 are perspective views of a binding device during thebinding operation.

DESCRIPTION OF THE PREFERRED EMBODIMENT

The following detailed description and appended drawings describe andillustrate various exemplary embodiments of the invention. Thedescription and drawings serve to enable one skilled in the art to makeand use the invention, and are not intended to limit the scope of theinvention in any manner. In respect of the methods disclosed, the stepspresented are exemplary in nature, and thus, the order of the steps isnot necessary or critical.

FIG. 1 shows a cut length of wire 1 that with several turns 3 is formedinto a coil 2, the turns 3 being held together by means of a bind 4. Thebind 4 can take the form of, for example, a tape with adhesive appliedto one side, the adhesive side of the tape embracing the turns 3, andthe adhesive sides of the tape-ends resting against each other. Theleading wire-end 5 has been processed, for example a crimp contact 6,possibly with a sealing seal, has been loaded. The leading wire-end 5may also be only stripped of insulation or not processed at all. Thetrailing wire-end 7 has been processed, for example a crimp contact 8,possibly with a sealing seal, has been mounted. The trailing wire-end 7may also be only stripped of insulation or not processed at all.

FIG. 2 shows a plan view of a wire processing machine 10 and FIG. 3 aperspective view of the wire processing machine 10.

Provided at the entry to the wire processing machine 10 is a wireadvancing device comprising a belt drive 11 and a length-measuringdevice 12. The belt drive 11 feeds a wire 13 to a first swivel arm 14with a first gripper 15. The belt drive 11 advances the wire 13 and thelength-measuring device 12 measures the advanced wire length, theadvanced wire length corresponding to the cut length of wire that is tobe manufactured and whose ends are to be processed. Not illustrated isthe wire stock, for example a wire drum or a wire reel.

By means of drives, the first swivel arm 14 can be set into a swivelingmovement symbolized with an arrow P1 and/or into a linear movement thatis symbolized with an arrow P2. By means of turning movement P1 andlinear movement P2, the first swivel-arm 14 as feeding device servesleading wire-ends 5 to processing stations 16 (for example crimp pressesand/or seal-loaders) arranged to the side of the longitudinal axis ofthe wire KL.

After the leading wire-end 5 has been processed, by means of grippers 15the first swivel arm 14 brings the leading wire-end 5 back into thelongitudinal axis of the wire KL. The wire 13 is than advanced by meansof the belt drive 11 until a coiler 17 can grip the leading wire-end 5.The belt drive 11 then advances the defined cut length of wire 1 that ismeasured by means of the length measuring device 12, and the coiler 17that is synchronized with the belt drive 11 simultaneously coils theadvanced cut-off length of wire into a coil 2 according to FIG. 1. Afterthe coil 2 has been manufactured, the cut length of wire 1 is cut offfrom the wire 13 by means of a cutting-off/insulation stripping unitand/or stripped of insulation with cutting-off/insulation-strippingblades 18. The leading wire-end of the next cut length of wire isgripped by the first swivel arm 14 by means of grippers 15 and fed tothe processing stations 16 for processing.

The trailing wire-end 7 of the coiled cut length of wire 1 is grasped bya second swivel arm 19 and set in a swiveling motion symbolized with anarrow P3 and/or in a linear motion symbolized with an arrow P4, thetrailing wire-end 7 being fed to processing stations 21 (for example,crimp presses and/or seal loaders) that are arranged at the side of thelongitudinal axis of the wire KL.

Before the trailing wire-end 7 is processed, the coil 2 is accepted bycoil grippers 22 of a stacker unit 23. The stacker unit 23 then moves inthe wire-advancing direction towards a deposit 24 until the stacker unit23 reaches a position approximately below the swivel arm drive 25 of thesecond swivel arm 19.

Before processing of the trailing wire-end 7 takes place, a tape station26 makes a cut length of tape ready for manufacturing the bind 4. Thecut length of tape is accepted by a binding device 27 of the stackerunit 23.

After processing of the trailing wire-end 7 has taken place, by means ofgrippers 20 the second swivel arm 19 brings the trailing wire-end 7 backinto approximately the longitudinal axis of the wire KL, and the stackerunit 23 is moved with the coil 2 further in the direction of the deposit24. During the travel of the stacker unit 23 to the deposit 24, the bind4 is manufactured by means of the binding device 27. The coil 2 withbind 4 is sorted according to good/bad criteria into one or other of thecontainers 31 of the deposit 24. A belt drive 28 moves the stackerdevice 23 by means of the belt 85 along a linear guide 29 that isarranged on a machine rack 30. Entered in FIG. 3 are the directionarrows x, y, and z. By means of the belt drive 11, the wire 13 isadvanced in the x direction, i.e. the longitudinal axis of the wire KLlies in the x direction. The stacker unit 23 moves in the x directionand lays the completed coil 2 in the z direction in the correspondingcontainer 31. For the purpose of pushing off the coil 2, the coiler 17is movable in the y direction as shown in FIG. 6.

FIG. 4 shows the coiler 17 that forms the cut length of wire 1 into acoil 2. Arranged in a circle peripherally on a rotatable coiling disk 32are supporting fingers 33 and tension fingers 34. Supporting fingers 33and tension fingers 34 bear the windings 3 of the coil 2. FIG. 7 showsdetails of the fingers 33, 34. The coiling disk 32 lies in the planethat is defined by the axes x and z and rotates about a horizontal axisof rotation 86 that runs parallel to the y axis. After processing of theleading wire-end 5 has taken place, the belt drive 11 advances the wire13 further. As soon as the leading wire-end 5 passes a first roller 35of a wire guide 38, the roller 35 and a counterfinger 42 are set in alinear motion P6 and the counterfinger 42 additionally in a rotatingmotion P7 by means of a drive unit 43. Simultaneously, the roller 35sets a guide finger 36 in a rotating movement P5 about a fixed axis 48,whereby the guide finger 36 moves to the counterfinger 42 and deflectsthe wire 13 on advancing in the direction of an opened coil gripper 37.Guide finger 36 and counterfinger 42 also serve as guiding aids forlateral guidance of the wire 13. The coil gripper 37 is arranged on thecoiling disk 32 within the circle that is formed by the fingers 33, 34.Roller 35, guide finger 36, counterfinger 42, and the drive unit 43 thatimparts the linear movement P6 form the fixed wire guide 38 relative tothe coiling disk 32. The length measuring device 12 measures theadvanced length of wire, and the control stops the belt drive 11 as soonas the length of wire needed to reach as far as the coil gripper 37 isattained. The coil gripper 37 that grasps the wire-end is then closed. Acoiler drive 39 drives the coiling disk 32, whereby the coiler drive 39and the belt drive 11 are synchronized when manufacturing the coil 2,the amount of wire that is advanced by the belt drive 11 issimultaneously coiled by the coiler disk 32, whereby the windings 3 ofthe arising coil 2 rest on the fingers 33, 34. After the coilingoperation, the coil 2 is grasped by the coil grippers 22 of the stackerunit 23, and the coiling disk 32 is moved in y direction by means of acylinder 41, whereby a remover 40 that is arranged locationally fixedrelative to the coiling disk 32 between the fingers 33, 34 pushes thecoil 2 off the fingers 33, 34. This is shown in detail in FIG. 6 andFIG. 7.

FIG. 5 shows the rear side of the coiler 17 and FIG. 6 the front side ofthe coiling disk 32 with linear guides 47. A motor pulley of the coilerdrive 39 drives a toothed belt 45 that drives a coiler pulley 46 andthereby the coiling disk 32. By means of the cylinder 41, the coilingdisk 32 along with the coiler drive 39 can be moved along linear guides47 in the y direction for the purpose of sliding the coil 2 off thefingers 33, 34, the coil 2 striking against the remover 40 and beingthus pushed over the fingers 33, 34. Referenced with 49 is an airconnection, via which compressed air can be fed to pneumatic units(coiler gripper 37, tension finger 34) of the coiling disk 32. The motorpulley 44 is connected to the coiler drive 39 by means of a coupling 50.

FIG. 7 shows details of the coiler 17, in particular the pneumatic unitssuch as coiler gripper 37 and tension finger 34 that are arranged on thecoiling disk 32. The supporting fingers 33 bear the windings 3 of thecoil 2. The tension fingers 34 bear and hold the windings 3 of the coil2. Each tension finger 34 has at its free end a nose 51 that restrainsthe coil 2 during the coiling operation. Moreover, the tension finger 34is rotatable about an axis 53 by means of a pneumatic drive 52. In theposition shown, the coil 2 can be slid off the fingers 33, 34 by meansof the remover 40. By means of the cylinder 54, the pneumatic drive 52actuates a lever that is rotatable about an axis 73 and which by meansof pins 57 that engage in elongated holes 56 rotates the tension finger34 about the axis 53 until the tension finger 34 is in the same positionas the supporting finger 33. In this position, the coiling disk 32 isready for the coiling operation.

FIG. 7 shows the coil gripper 37 for holding the leading wire-end 5. Thetwo gripper halves 58, which are shown in closed position, arepneumatically rotatable and openable about an axis 59 and by means offingers 60 grasp the wire-end.

FIGS. 8 to 10 show a tape station 26 on which an adhesive tape 61 with alayer of adhesive applied to one side is being prepared for a lengththat is necessary for the bind 4. A stock of tape 62 rests on a tapedisk 64 which, by means of a cylinder 63, is height-adjustable in the zdirection, which to improve accessibility for the first, manualthreading of the adhesive tape 61 is in the upper position. Arranged onthe tape disk 64 is a finger 65 with two finger pins 66. Thenon-adhesive or dry side of the adhesive tape 61 is pulled manually overthe finger pin 66 that is close to the disk, and the starting end of thetape firmly bonded onto the side with the adhesive layer on the fingerpin 66 that is distant from the disk. The manual threading is thuscomplete, and the tape disk 64 is lowered and, by means of the cylinder67, swiveled until the adhesive tape 61 as shown in FIG. 9 is in linewith an extendable diversion pin 68 and a tape gripper 69 with cuttingblade 70. The tape gripper 69 is then closed and the adhesive tape 61cut through by means of the cutting blade 70. As shown in FIG. 10, thetape disk 64 is swiveled back into the starting position. The remnant oftape that adheres to the finger pin 66 distant from the disk is removedmanually. A tape pull-off gripper 72 that is linearly actuatable in they direction by means of a pneumatic linear unit 71 is then moved in theopen state between the diversion pin 68 and the tape gripper 69. Thetape pull-off gripper 72 is then closed, and the tape gripper 69 opened.The linear unit 71 now moves the tape pull-off gripper 72 back, togetherwith which the adhesive tape 61 is pulled out of the tape stock 62 bythe length that is necessary for manufacturing the bind 4.

Instead of the adhesive tape 61, a tape with comparable properties canbe used. Also suitable, for example, is a plastic tape that has on oneside hemispherical heads on short stems arranged in wavelike patternwhich, when pressed together, allow formation of a permanent orreleasable fastening.

FIG. 11 and FIG. 12 show the stacker unit 23 when receiving the preparedadhesive tape 61 from the tape station 26. FIG. 11 shows the stackerunit 23 together with parts of the tape station 26 from below, whereinfor greater clarity only the upper coil gripper 22 is made visible, thelower coil gripper is not shown in FIG. 11. The coil grippers 22 are notyet closed, in FIG. 1 the coil 2 is still held firmly by the fingers 33,34 of the coiling disk 32. The adhesive tape 61 that is pulled out ofthe tape stock 62 by the tape pull-off gripper 72 is held firmly byroller grippers 76 that each consist of a rotatable roller arm 74 and alocationally fixed pressure arm 75, the tape pull-off gripper 72 havingalready been opened. The roller grippers 76 are part of the bindingdevice 27. On closing the tape gripper 69, the adhesive tape 61 thatruns in the y direction is cut through at the point marked with dots 77by means of the cutting blade 70. The wire-stock end of the adhesivetape 61 is held firmly by the tape gripper 69. As shown in FIG. 12, thestacker unit 23 and the binding device 27 are ready for the movement inthe x direction to the deposit 24 and on their way to the deposit 24 forthe bind 4 to be manufactured. The coil 2 has been accepted from thecoiler 17 by the coil gripper 22 and is held firmly by the latter. Thecut length of adhesive tape 61 is held firmly by means of the rollergripper 76 and is ready for the binding operation.

FIG. 13 and FIG. 14 show the binding device 27 during the bindingoperation. For greater clarity, the coil grippers 22 are not visiblyshown. The roller arm 74 of the roller gripper 76 can execute therotating movement P8 and is rotatable by means of a pneumatic rotatorunit 78. A roller 79 of the roller arm 74 presses the adhesive tape 61against the pressure arm 75, whereby the non-adhesive side of theadhesive tape 61 rests on the pressure arm 75 and the adhesive layer ofthe adhesive tape 61 rests on the roller 79. Roller gripper 76 androtator unit 78 are movable in the y direction by means of a pneumaticlinear unit 80, whereby the two roller grippers 76 are movable towardsor away from each other. The two pneumatic linear units 80 are alsomovable in the x direction by means of a pneumatic linear unit 81comprising push-rods 82 and cylinder 83. As shown in FIG. 13, the rollergrippers 76 are movable in the x direction against the wire advancedirection to the coiler 17, whereby the adhesive layer of the adhesivetape 61 comes to rest on the coil 2. Through the relative movement ofthe roller grippers relative to the coil 2, the free ends 84 of theadhesive tape 61 that are shown in FIG. 11 are pulled over the rollers79 without leaving them. In the end position of the roller grippers 76that is shown in FIG. 13, the adhesive tape 61 is ready formanufacturing of the bind 4. To manufacture the bind 4, the two rollergrippers 76 are moved in the y direction towards each other, whereby thepressure arms 75 lay the adhesive tape 61 around the coil 2, and the tworemaining tape ends press against each other adhesive layer to adhesivelayer, the ends 84 thereby leaving the rollers 79. Subsequently, thelinear unit 81 pushes the linear unit 80, and with it the roller gripper76, into the end position in the x direction shown in FIG. 14. The coil2 with the bind 4 is now ready for handover to the deposit 24 in one ofthe containers 31. Handover is effected by opening the coil grippers 22.

In accordance with the provisions of the patent statutes, the presentinvention has been described in what is considered to represent itspreferred embodiment. However, it should be noted that the invention canbe practiced otherwise than as specifically illustrated and describedwithout departing from its spirit or scope.

1. A device for accepting from a coiler a cut length of wire that hasbeen formed into a coil and transporting the coil to a deposit,comprising: coil grippers of a stacker unit for firmly holding the coil;and a binding device for providing the coil with a bind while saidstacker unit is transporting the coil to the deposit.
 2. The deviceaccording to claim 1 including a linear guide and a drive for movingsaid stacker unit between the coiler and the deposit, and said bindingdevice being arranged on said stacker unit, and opposite said stackerunit is a locationally fixed tape station that prepares a tape from atape stock for use as the bind.
 3. The device according to claim 2wherein said tape station has a tape gripper with a cutting blade tofirmly hold and cut the tape and a tape pull-out gripper to pull alength of tape necessary for the bind out of the tape stock.
 4. Thedevice according to claim 2 wherein said binding device, for the purposeof accepting the length of tape from the tape station, has two rollergrippers that hold the length of tape firmly before the tape grippercuts through the tape stock.
 5. The device according to claim 4 where ineach said roller gripper is provided with a rotatable roller arm havinga roller and a pressure arm, said roller and said pressure arm firmlyholding the length of tape.
 6. The device according to claim 5 where infor the purpose of manufacturing the bind, said two roller grippers aremoved towards each other by associated linear units and moved oppositeto the direction of travel to the deposit by another linear unit,whereby the length of tape is laid around the coil.
 7. A method foraccepting from a coiler a cut length of wire that is formed into a coiland transporting the coil further to a deposit comprising the steps of:firmly holding the coil with coil grippers of a stacker unit; and whilethe coil is moved by the stacker unit to the deposit, providing the coilwith a bind using a binding unit.
 8. The method according to claim 7including preparing a tape for use as the bind from a tape stock using atape station that is stationary relative to the stacker unit.
 9. Themethod according to claim 8 including accepting and firmly holding atape stock with two roller grippers of the binding unit and then cuttingthrough the tape stock with tape grippers of the tape station.
 10. Themethod according to claim 9 including operating said two roller grippersto lay the tape around the coil to provide the bind.